A Novel High-Fidelity Simulation for Finishing Operations: Hybrid Image Mosaic and Wavelet Decomposition

In finishing simulations, achieving accurate results can be challenging due to the minimal amount of material removal and the limited measurement range of surface micro-topography instruments. To overcome these limitations, a novel high-fidelity modeling method combining image mosaic and wavelet decomposition technologies is proposed in this paper. We achieve the stitching of narrow field and high pixel micro morphology images through four steps: image feature extraction, overlapped feature matching, feature fusion, and stitching effect evaluation. On this basis, the wavelet decomposition method is employed to separate detection signals based on their respective frequencies, allowing the establishment of a datum plane and a roughness surface. The point cloud model undergoes a transformation into a continuous geometric model via the Poisson reconstruction algorithm. In the case study, four sample images of an aluminum alloy sheet after barrel finishing were collected using the ZeGage Plus optical profiler. Each image has an actual size of 834.37 μm × 834.37 μm. Subsequently, a comparison was carried out between the physical and simulation experiments. The results clearly indicate that the proposed method has the potential to enhance the accuracy of the finishing simulation by over 30%. The error between the resulting model and the actual surface of the part can be controlled within 1 μm.